Installation Instructions

for 3.0-liter V6
Supercharger Kit

1997-2000 Camry,1999-2000 Solara,

1997-1999 Avalon

Supercharger Kit Part Numbers: 00646-17620-301

00646-17620-302
00646-17620-303
00646-17620-304
 Installation Instructions
for 3.0-liter V6 Supercharger Kit
1997-2000 Camry,1999-2000 Solara,
1997-1999 Avalon

Section 1: Installation Preparation

Kit Contents
Qty Description Connection or Installation Location Page Part Number
1 Supercharger/Manifold Assembly - Camry/Solara Main Assembly - Bolts directly to OE Manifold. 11 00646-17620-307
1 Supercharger Belt - Camry/Solara Replaces OE Alternator Belt. 15 00646-17620-330
1 Assembly, Idler Plate and Pulley - Camry/Solara Installed on front of engine. 14 00646-17620-320
1 Convoluted EGR Tube - 5 Speed Replaces OE EGR Tube. 10 17620-355
or Convoluted EGR Tube - Automatic Replaces OE EGR Tube. 10 17620-360
1 Kit, Literature
1 Manual, 3.0 Installation
1 Warranty Card Fill out and send in to TRD.
1 Warranty Certificate Keep in glove compartment.
2 Decal, Kazuma Place as desired. Usually placed on OE Timing Belt Cover.
1 EO Sticker Place underneath hood. 17
1 Belt Routing Sticker Place underneath hood. 17
1 Premium Fuel Sticker Place one on or near fuel gauge, the other inside fuel filler door. 17
Supercharger Brochure, Catalogs, Promo. Matl.
1 Idler Plate Installation Kit
2 Bolt, Allen Head - 10mm x 1.25mm x 30mm Attaches Idler Plate to engine. 14
1 Bolt, Counter Sunk - 10mm x 1.25mm x 100mm Alternator Pivot Bolt - Installed through Idler Plate and Alternator Pivot Bolt Spacer. 14
1 Spacer, Alternator Pivot Bolt Installed between Idler Plate and Alternator Pivot Mount. 14
1 Bracket, Drive Plate Attaches Idler Plate to engine. 14
1 Bolt, Counter Sunk - 8mm x 1.25mm x 20mm Used to attach Drive Plate Bracket to engine. 14
1 Washer, Flat - 8mm Used with 8mm x 1.25mm x 20mm Counter Sunk Bolts. 14
1 Nut, Nylock - 8mm x 1.25mm Used with 8mm x 1.25mm x 20mm Counter Sunk Bolts. 14
1 Bolt, Hex Head - 10mm x 1.25mm x 100mm Attaches Engine Moving Control Rod through Idler Plate and Gooved Pully. 16
1 Washer, Flat - 10mm Used with 10mm x 1.25mm x 100mm Hex Head Bolt. 16
1 Nut, Nylock - 10mm x 1.25mm Used with 10mm x 1.25mm x 100mm Hex Head Bolt. 16
1 Hose, Connector and Hardware Kit
2 Stud, 8mm x 1.25mm x 50mm Attach to bottom two holes on Supercharger Intake Plenum to mount Throttle Body Assembly. 13
1 Vacuum Hose - 5/16" x 13" long Connects PCV valve to Supercharger Assembly. 10, 11
1 Vacuum Hose - 3mm x 8" long Connects PWM VSV to Vacuum Control Tank (VCT). 13, 18, 19
2 Vacuum Hose - 3mm x 15" long One hose connects Vacuum Control Tank (VCT) to EGR valve and the other hose connects
Vacuum Control Valve (VCV) to Supercharger Assembly. 13, 18, 19
3 Hose Clips, Black Plastic Retains vacuum hoses in their proper places. 13, 18, 19
1 Valve, IAC, Check Installed near IAC valve. 7
2 Bolt, Hex Head - 6mm x 1.0mm x 18mm Attaches EGR valve to engine. 12
2 Washer, Flat - 6mm Used with 6mm x 1.0mm x 18mm EGR bolts. 12
2 Vacuum Caps Used to cap off Acoustic Control Induction System (ACIS) VSV and associated pipe. 13, 18, 19
1 90 degree elbow Attaches vacuum hose to EGR valve. 13, 18, 19
1 Barb, 1/8" 1 each placed in 90 degree elbow. 13, 18, 19
3 Large Zip Tie Used to tie engine main wiring harness to low pressure refrigerant line. 10
6 Medium Zip Tie 1 used to tie PVC hose to engine, 1 used to tie unused vacuum tank hoses to engine harness,
2 used to tie ground straps and coolant recovery hose to Engine Moving Control Rod
and 2 used to tie Vacuum Control Tank (VCT) to front of engine. 10, 13, 17, 18, 19
Miscellaneous
1 Strut Tower Brace Used only with Kits 00646-17620-301 and 00646-17620-302 17
Service Parts - not included as spare in kit.
2 per assy. Pulley and Bearing Assembly, Smooth For use as service items only. 00602-17620-019
2 per assy. Pulley and Bearing Assembly, Grooved For use as service items only. 00646-17620-325

Tools Recommended
Basic Tools Basic Metric Socket, Allen & Open-End Wrench Sets Safety Tools Safety Goggles
1/2" Wide Masking Tape for Labeling Hardware and Parts Special Tools Tensionometer (available from Kent-Moore, 1-800-345-2233) See figure 48
A Clean Work Bench Toyota Repair Manual (available from Toyota, 1-800-622-2033)
A Parts Tray Accessories TRD shift control unit, part # 00646-17620-375
Rags or Shop Towels (Automatic transmission vehicles only)
 Installation Instructions
for 3.0-liter V6 Supercharger Kit
1997-2000 Camry,1999-2000 Solara,
1997-1999 Avalon

Section 2: Removal Procedure

A. Preparation for Removal of Stock Air
Intake Chamber (Manifold)

• Before you begin, TRD recommends that you thoroughly clean

the engine and engine compartment. If you don’t, grease buildup
on parts could become dislodged during the procedure and fall
into the engine.

• Make sure the engine has cooled fully before you begin.
• Toengine’s
help you later, you might want to draw diagrams of your
vacuum hose routing before you disconnect anything.
Figure 1
However, some of the vacuum connections on your stock air intake
chamber may not be the same as those on the supercharger. To
ensure the proper hose connections, please refer to the diagrams in
the back of this book.

• The TRD supercharger kit has been designed to reuse most of the
stock nuts and bolts. Therefore, as you remove them, keep them A
with their components or label them for location. This will assure
a faster, easier installation.

B. Removal of Stock Intake Chamber

1. Disconnect the ground cable from the battery. B

2. For Solara models, remove the OEM strut tower brace. Figure 2

3. Remove the V-bank cover (figure 1).

4. Unplug the two engine-to-body ground wires

(see arrow A, figure 2).

5. Remove the coolant recovery hose from the water outlet housing
(see arrow B, figure 2).

6. Loosen the clamps from the throttle body air intake tube
(see arrows A, figure 3).

7. Remove the vent hose from the cam cover

(see arrow B, figure 3).

8. Remove the throttle body air intake tube from the engine. Figure 3

Page 1
 Installation Instructions
for 3.0-liter V6 Supercharger Kit
1997-2000 Camry,1999-2000 Solara,
1997-1999 Avalon

TIP: The gravel guard consists of two pieces but it’s much
easier to install if you remove it as a one-piece assembly.
9. Unplug the connectors from the throttle position sensor (A) and
the IAC (Idle Air Control) valve (B) (see arrows, figure 4).

10. Unplug the connectors from the EGR position sensor (A)
and the EGR gas temperature sensor (B) on the EGR valve
(see arrows, figure 5).

11. Remove the brake servo vacuum hose from the air intake
chamber (see arrow, figure 6).

Figure 4

Figure 5

Figure 6

Page 2
 Installation Instructions
for 3.0-liter V6 Supercharger Kit
1997-2000 Camry,1999-2000 Solara,
1997-1999 Avalon

12. Remove the two bolts and the two nuts from the throttle body
(see arrows, figure 7).

13. Remove the throttle body and set it aside. Do not disconnect
any cables.

14. Remove and save the throttle body’s metal gasket. It will be reused.
If gasket needs replacement, use Toyota part # 22271-20010.

15. Disconnect the evaporative (EVAP) canister vacuum hose from the
air intake chamber (see arrow, figure 8).

16. Remove the upper bolt holding the chamber stay to the back of
the air intake chamber (driver’s side) and move the stay enough Figure 7
to gain access to the nuts holding the EGR valve pipe
(see arrows, figure 9).

17. Remove the four nuts from the EGR pipe (see arrow, figure 9)
and remove the pipe and the two gaskets. The gaskets will be
reused in the installation procedure. If the gaskets need to be
replaced, use Toyota part # 25627-20010.

Figure 8

Figure 9

Page 3
 Installation Instructions
for 3.0-liter V6 Supercharger Kit
1997-2000 Camry,1999-2000 Solara,
1997-1999 Avalon

18. Remove the three nuts from the EGR valve and remove the valve
with the gasket from the air intake chamber (see arrows,
figure 10). The gasket will be reused in the installation
procedure. If the gasket needs to be replaced, use Toyota part
# 25627-20010.

19. Remove the Vacuum Switching Valve (VSV)-to-EGR hose from the
EGR valve (see arrow, figure 11).

20. Remove the two ground straps from the air intake chamber
(see arrow, figure 12).

Figure 10

Figure 11

Figure 12

Page 4
 Installation Instructions
for 3.0-liter V6 Supercharger Kit
1997-2000 Camry,1999-2000 Solara,
1997-1999 Avalon

21. Remove the Acoustic Control Induction System (ACIS) vacuum

hose from the VSV (see arrow, figure 13).

22. Remove the nut holding the power steering line to the passenger’s-
side engine hanger and pull it back enough to access the engine
hanger bolt (see arrow, figure 14).

23. Remove the bolt holding the engine hanger to the passenger’s side
of the air intake chamber (figure 14).

24. Remove the ground strap from the back of the air intake chamber
(see arrow, figure l5).

25. Unclip the spark plug wire loom and set aside. Figure 13

Figure 14

Figure 15

Page 5
 Installation Instructions
for 3.0-liter V6 Supercharger Kit
1997-2000 Camry,1999-2000 Solara,
1997-1999 Avalon

26. Remove the two VSV rack nuts and lay the rack to one side.

27. Disconnect the two vacuum hoses from the air intake chamber
(see arrows, figure 16). One goes to the vacuum tank,
the other to the Vacuum Control Valve (VCV).

28. Remove the two Allen bolts and the two nuts from the air intake
chamber (see arrows, figure 17).

29. Lift up on the air intake chamber and tilt it to the rear, remove the
PCV hose from the bottom (see arrow, figure 18)
then remove the air intake chamber from the vehicle.
Figure 16

Figure 17

Figure 18

Page 6
 Installation Instructions
for 3.0-liter V6 Supercharger Kit
1997-2000 Camry,1999-2000 Solara,
1997-1999 Avalon

30. With the EGR valve off the vehicle, remove the EVAP canister hose
bracket from the valve (see arrow, figure 19). The bracket
won’t be used in the installation procedure.

31. To keep out debris, cover the intake ports with a clean shop cloth.

32. Cut the IAC hose and insert TRD’s one-way valve with the mark
closest to the throttle body (see arrow, figure 20).

CAUTION: Make sure you don’t cut the fuel line or

water bypass hoses instead.

Figure 19

Figure 20

Page 7
 Installation Instructions
for 3.0-liter V6 Supercharger Kit
1997-2000 Camry,1999-2000 Solara,
1997-1999 Avalon

33. Remove the three bolts from the passenger’s-side engine mount
stay (see arrows, figure 21). For manual transmission vehicles,
remove the second engine mounting stay (see arrows, figure 22).
Neither stay will be reused with the supercharger. Bolt (A)
(Figure 21) will be reused in the installation procedure.

34. Remove the center bolt from the engine moving control rod
(see arrow, figure 23). This bolt will not be reused.

35. Remove the two bolts holding the #2 engine mounting bracket
from the engine and remove the bracket (figure 24). Bolts and
bracket will not be reused.
Figure 22

Figure 21 Figure 23

Figure 24

Page 8
 Installation Instructions
for 3.0-liter V6 Supercharger Kit
1997-2000 Camry,1999-2000 Solara,
1997-1999 Avalon

36. Slide the relay box from its bracket to provide access to the
alternator adjuster bolt (figure 25).

37. Loosen the alternator pivot bolt, the adjusting lock bolt and
adjusting bolt (see arrows, figure 26) and remove the
alternator belt. The belt will not be reused with the supercharger.

38. Remove the stock alternator pivot bolt, nut and alternator support
bracket. Reinstall the nut on the stud (see arrows, figure 27).
The bracket and OE pivot bolt will not be reused.

Figure 25

Figure 26

Figure 27

Page 9
 Installation Instructions
for 3.0-liter V6 Supercharger Kit
1997-2000 Camry,1999-2000 Solara,
1997-1999 Avalon

39. Using the original equipment (OE) EGR metal gaskets and
nuts, install the TRD-supplied convoluted EGR pipe to the
two lower studs on the EGR cooler and for now, leave the nuts
loose so that the tube can be easily maneuvered (figure 28).

40. Unclip the main engine wiring harness and using the large
TRD-supplied zip ties, attach the harness to the low-pressure
refrigerant line as illustrated in (figure 29). Trim off any
excess zip tie material.

41. Install the 5/16" x 13" TRD-supplied vacuum hose to the

PCV valve and using one medium TRD-supplied zip tie,
attach the hose to the injector wiring loom
(see arrow, figure 30). Figure 28

Figure 29

Figure 30

Page 10
 Installation Instructions
for 3.0-liter V6 Supercharger Kit
1997-2000 Camry,1999-2000 Solara,
1997-1999 Avalon

Section 3: Installation Procedure

A. Installation of TRD Supercharger Assembly

1. Position the supercharger assembly just above the engine.

2. Install the PCV valve hose to the supercharger assembly

(see arrow, figure 31) and maneuver the supercharger onto
the engine. Install the OE bolts and nuts previously removed in
section 2, part B, step 28 and hand tighten for now.

3. Remove the bolt from the supercharger’s drive housing as shown

in (figure 32), attach the two ground wires, reinstall the bolt
and torque to 20 lbs. ft. Figure 31

4. Attach the third ground wire to the back of the supercharger

assembly and torque to 12 lbs. ft. (see arrow A, figure 33).

5. Bolt the passenger’s-side engine hanger to the back of the

supercharger assembly and hand tighten for now
(see arrow B, figure 33).

Figure 32

A
B

Figure 33

Page 11
 Installation Instructions
for 3.0-liter V6 Supercharger Kit
1997-2000 Camry,1999-2000 Solara,
1997-1999 Avalon

6. From the driver’s side, remove the locknut and washer from
the back of the supercharger assembly. Install the chamber
stay over the stud and collar using the washer and locknut.
Hand tighten for now (see arrow, figure 34).

7. Torque the supercharger bolts and nuts to 32 lbs. ft. Torque the
passenger’s-side engine hanger to 29 lbs. ft. and reinstall the
power steering line onto the stud using the OE nut and
tighten until snug (69 lbs. in.). Torque the driver’s-side
chamber stay to 14 lbs. ft.

8. Position the EGR valve and its gasket on the supercharger

assembly, install the two TRD-supplied 6mm x 18mm bolts
and 6mm washers and hand tighten for now (figure 35). Figure 34
The bottom bolt hole on the EGR valve is not used with
the supercharger.

9. Position the gasket and TRD-supplied convoluted EGR pipe

onto the EGR valve and tighten. Torque all four EGR pipe
nuts and two EGR valve bolts to 9 lbs. ft.

10. Install the brake servo vacuum hose to the vacuum fitting on
the air intake chamber (see arrow, figure 36).

Figure 35

Figure 36

Page 12
 Installation Instructions
for 3.0-liter V6 Supercharger Kit
1997-2000 Camry,1999-2000 Solara,
1997-1999 Avalon

11. Install the two TRD-supplied 8mm x 50mm studs into the
two bottom holes on the supercharger intake plenum.

Note: When installing the 8mm x 50mm studs, make sure

the short threaded end of each stud is installed into the
supercharger assembly.
Install the throttle body and gasket. Install the EGR gas
temperature bracket, two OE nuts and two OE upper bolts and
torque each to 14 lbs. ft. (see arrows, figure 37).

12. Plug in the connectors to the IAC valve, the throttle position
sensor, the EGR gas temperature sensor and the EGR position
sensor (refer to section 2, part B, steps 9 and 10). Figure 37

13. Install the VSV rack with the original nuts and tighten
until snug.

14. Re-attach the spark plug wire loom.

15. Cover the two VSV vacuum ports with the TRD-supplied caps
(see arrows, figure 38) and using one TRD-supplied
medium zip tie, tie the two hoses (A & B) out of the way.
They are no longer needed. Refer to the diagrams in the back
of this book.

16. Install the TRD-supplied 3mm x 8" and the two 3mm x 15"
vacuum hoses according to the diagrams in the back of this A & B
book. Reinstall the EVAP canister vacuum hose to the air
intake chamber. Figure 38

Note: When installing the 90o elbow to the EGR valve, a

small portion will have to be trimmed in order for the
elbow to fit properly.

17. Remove the two top grooved pulleys from the idler plate.
Note the position of the collars for reinstallation
(see arrow, figure 39).

Figure 39

Page 13
 Installation Instructions
for 3.0-liter V6 Supercharger Kit
1997-2000 Camry,1999-2000 Solara,
1997-1999 Avalon

18. Install the TRD idler pulley plate using the TRD-supplied
10mm x 30mm Allen-head bolts and leave the bolts loose
for now (see arrows, figure 40).

19. Install the TRD-supplied 10mm x 100mm flat-head

alternator pivot bolt through the idler plate & the TRD-
supplied spacer. Hand tighten to the alternator mount.
(see arrow, figure 41).

20. Install the TRD-supplied plate support bracket with the TRD-
supplied 8mm x 20mm flat-head bolt, 8mm washer and
8mm locknut. Mount the bracket to the water outlet housing
using bolt (A) from Section 2, Part B, Step 33.
(see arrows, figure 42) Hand tighten for now. Figure 40

Figure 41

Figure 42

Page 14
 Installation Instructions
for 3.0-liter V6 Supercharger Kit
1997-2000 Camry,1999-2000 Solara,
1997-1999 Avalon

21. Tighten all bolts according to the sequence and torque specs
shown in figure 43.

22. Install the TRD-supplied supercharger belt according to

figures 44 and 45.

23. Install the spacer collar to the inside of the idler pulley
(see arrow, figure 46).

IMPORTANT: In order for the TRD-supplied

supercharger belt to line up properly, the spacer
collar placed onto each of the two grooved idler
pulley shafts must face the engine.
Figure 44

Figure 43 Figure 45

Figure 46

Page 15
 Installation Instructions
for 3.0-liter V6 Supercharger Kit
1997-2000 Camry,1999-2000 Solara,
1997-1999 Avalon

24. Install the two grooved idler pulleys and the engine moving
control rod using the TRD-supplied bolts and locknuts
(figure 47) and torque to 20 lbs. ft.

Note: Use the TRD-supplied flanged 10mm x 100mm bolt,

10mm washer and 10mm locknut with the engine
moving control rod. Install this bolt and pulley first.

25. Using the Kent-Moore tensionometer, tension the belt

according to new-belt specs—120 lbs. (figure 48).

26. Torque the alternator adjuster lock bolt to 13 lbs. ft.

27. Install the relay in its bracket. (Refer to figure 25) Figure 47

28. Plug in the two engine-to-body ground wires

(see arrows, figure 49).

Figure 48

Figure 49

Page 16
 Installation Instructions
for 3.0-liter V6 Supercharger Kit
1997-2000 Camry,1999-2000 Solara,
1997-1999 Avalon

29. Connect the coolant recovery hose to the water outlet housing
and secure the hose and the ground wires to the engine moving
rod with the two TRD-supplied medium zip ties (see arrow,
figure 50).

30. Install the air intake tube to the throttle body and tighten its
clamps. Install the vent hose to the cam cover.

31. Connect the ground cable to the battery, run the engine for
about 15 minutes and recheck the belt tension. It should fall
between 70 and 90 lbs.

32. For Solara models, install the TRD-supplied strut tower brace
and torque the nuts to 59 lbs. ft. Figure 50

33. Re-check all vacuum lines & connections. Re-install

V-bank cover.

34. Apply the premium-fuel stickers to the fuel gauge and

fuel filler door.

35. Apply a TRD belt routing sticker and the Executive Order
(EO) label to the underside of the hood. The EO will alert
state smog inspectors that the TRD supercharger has been
certified emissions legal in all 50 states.

Page 17
 Installation Instructions
for 3.0-liter V6 Supercharger Kit
1997-2000 Camry,1999-2000 Solara,
1997-1999 Avalon

Figure A
Year
1997
Model
Avalon, Camry

Year
1998
Model
Camry
Notes:

Figure B
Year
1998
Model
Avalon

Notes:

Page 18
 Installation Instructions
for 3.0-liter V6 Supercharger Kit
1997-2000 Camry,1999-2000 Solara,
1997-1999 Avalon

Figure C
Year
1999
Model
Avalon

Notes:

Figure D
Year
1999-2000
Model
Camry, Solara

Notes:

Page 19

Symptom
Idles rough, “pings”
(Trouble Code PO171—Lean Code)
Pings during acceleration
Low boost
Makes a moderately loud noise
under full throttle—intake noise
Rattling at idle—goes away
at just above idle
Rattling above idle—gets louder
with higher rpm or louder with
more boost pressure
Supercharger belt jumps
across pulley grooves
Supercharger belt leaves grey/black
powder on drive housing and other areas
Supercharger appears to leak oil
from drive housing
Page 20
Installation Instructions
for 3.0-liter V6 Supercharger Kit
1997-2000 Camry,1999-2000 Solara,
1997-1999 Avalon
Possible Causes Corrective Action
Lean condition— Check vacuum line connections for leaks and cracked ends.
vacuum leak
Review factory service manual for proper factory vacuum routing.
Review instructions for proper vacuum line routing.
Check installation of the TRD throttle body gasket. If gasket is installed
improperly, a vacuum leak will occur.
Recheck torque on throttle body bolts.
Leak at manifold gasket.
Recheck torque on intake manifold bolts.
Low octane fuel Fill tank with premium fuel. BE SURE TO USE 92 OR HIGHER OCTANE FUEL.
Computer has yet to Drive several hundred miles in different driving modes
adjust to supercharger (Not all steady-state highway cruising, for example).
Insufficient fuel delivery Fuel filter old—replace. Follow factory diagnosis and replacement procedures.
Fuel pressure low. Follow factory diagnosis and replacement procedures.
Injector(s) clogged. Follow factory repair/replacement procedures.
Belt slipping Recheck belt tension using tensionometer.
Check condition of belt—oily, worn, high mileage.
Air filter dirty Check/replace air filter. A dirty filter restricts the air intake. TRD dyno
tests have shown that the TRD air filter is among the best on the market
for flow and filtering characteristics.
Throttle not fully opened Recheck and adjust the throttle cable and transmission cable. Be sure that
full depression on the gas pedal achieves full throttle opening at the
throttle body.
Normal supercharger No remedy. Superchargers are an air pump and the pumping action is
sound impossible without some noise. Call TRD for further diagnosis.
Normal supercharger Slight rattle at idle is normal, but only if noise sharply decreases at
sound 400 - 500 rpm above idle. Call TRD for further diagnosis.
Drive housing bearing Call TRD for further diagnosis.
wear or backlash
Idler pulley bearing Diagnose by removing belt from supercharger and running engine for less than
wear or excessive freeplay 30 seconds. If noise continues, source of problem is not within supercharger.
Belt too loose Check and re-tension belt as necessary. BE SURE TO USE A TENSIONOMETER.
Misaligned pulley/idler Check to be sure that the collars placed onto the pulley shafts face towards the engine.
Damaged pulleys Be sure that the pulleys all run true—no eccentricity.
Loose pulleys Check to be sure that the crankshaft pulley is properly tightened. Re-tighten
to specifications given, follow the procedures in the factory manual.
Normal break-in residue No corrective action. Belt should be fully broken in after 2000 miles.
Front seal not fully No immediate corrective action. Seal should be fully mated to pulley after
broken in 2000 miles. If leaking continues, contact TRD.
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NOTES

Page 21
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©2000 TRD U.S.A., Inc. Printed in USA 00602-05100-221